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GM/Chevy Trucks

You will find that GM Trucks are a common source of aftermarket
fuel repair jobs. Predominantly, model years
from the mid-1990s to current models have known repair problems with
the following components:

The OE roller vane-style pump is under-designed for the high pressure
of the CPI fuel system and its high electrical draw can melt the
weak connectors.

The OE pump design is ill-suited to the vibration and shock that
the trucks encounter while in service.

FIND OUT WHY the failure occurred before buying parts:

Is there less than 13.5 volts at the pump?

The repair requires a new wiring harness.

Note that Carter® includes wiring harnesses in the box for applications with known wiring issues.

Is the gas tank rusting inside or rusted through?

The repair requires a new tank.

Is the strainer black with grime? Or discolored, appearing packed with contaminants?

The repair requires you to wash out the contamination and dry the tank.

Carter offers a robust turbine pump that is one of the best on the market,
but all professionals know that installing a pump without cleaning the tank
will lead to a comeback within a few months!

PROBLEMOn certain GM in-tank electric pump hanger assemblies, a faulty electrical
connector can cause severe voltage drop (or total loss of voltage) to the pump,
a failure mode that often leads to improper diagnosis. Always remove and inspect
the hanger wire harness when servicing these pumps! First inspect the electrical
connector at the pump and underside of hanger. A “sooty”
carbon deposit on the plastic connector, or melted wire insulation, could be
a sign that the real problem is not the pump, but the wire harness. Replacing
the pump without correcting the wiring will simply lead to another premature
failure.

PROBLEMCertain GM fuel pump applications are prone to electrical connector failures.
Usually, the electrical connector on the vehicle wiring harness that plugs
into the fuel pump module is at fault. The positive or negative terminal within
this connector begins losing continuity, creating a substantial voltage drop.
The heat generated from the arcing and voltage drop melts the plastic around
the positive or negative terminal. Where the terminal protrudes from this plastic
connector, the plastic should have a pyramid shape. The heat generated by a
failed terminal will cause the plastic around it to melt into a spherical shape.
In other instances a blackening of the plastic around the terminal will be
evident. The location of this faulty connection makes it impossible to diagnose
the problem using a voltage drop test. So it’s important to carefully
inspect the connector on the old module and the connector on the vehicle body
harness for evidence of this failure.

SOLUTIONIf a failure is suspected, the section of the vehicle wiring harness with the
faulty connector must be replaced. If your vehicle requires the white 4-pin,
four-cavity connector, purchase Carter® connector repair kit 888-553. If
it requires the black 4-pin, four cavity connector, purchase kit 888-543. If
it requires the 4-pin or 5-pin, six-cavity connector, purchase kit 888-544.

Carter wire harnesses for GM module assemblies include:

Wire insulated with “ETFE” grade covering

Brilliant copper wire terminals

Glass-filled nylon cover connectors and pump connectors

Special addendum to GM vehicle to module wiring harness

GM announced a wiring harness recall in 2005 regarding the Suburban model
years 2000-2001. However, GM has issued a dealer bulletin to repair Metri-Pac® 150
connectors on the following trucks and SUVs: